Welding and Joining

Fusion welding: Joining of materials is an important element for the design of a component. Fusion welding is associated with the application of intense heat source, thermalization of the process, melting and solidification, material flow, and generation of residual stress and distortion. In advanced welding laboratory, the fusion welding of similar and dissimilar materials using laser, microplasma arc, gas tungsten arc and resistance spot welding processes have been performed. Currently, the focus of the work is confined to join very thin sheet, so called microscale welding processes. The minimum thickness of the sheet (0.5 mm) in butt joint configuration has been joined by using laser and micro plasma arc welding processes. Several high melting point materials like stainless steels, low carbon steels, maraging steels, cupronickel, inconel, titanium alloys, and advanced high strength coated steel are welded and related metallurgical issues are addressed. The management of residual stress and distortion are primary concern in sheet metal welding process.

Friction stir welding (FSW): The joining of aluminium and copper is performed using plasma assisted hybrid FSW process. The tool offset is optimized to equilibrate the flow stress of two different materials. FSW is also performed for joining 6000 series aluminium alloys and magnesium alloys.